Polyester Pile Fabric Having Excellent Soft Hand, Abrasion Resistance And Bathochromic Effect

ABSTRACT

The pile fabric having a very soft hand, a high abrasion resistance and a good bathochromic effect comprises a ground structure portion constituted from a polyester filament yarns and having a knitted or woven structure and a pile portion comprising polyester filaments knitted or woven into the ground structure portion. The polyester filaments for the pile portion have a flat cross-sectional profile with a flat ratio of 2 to 6, and an individual filament thickness of 0.5 to 1.5 dtex. In the flat cross-sectional profile, least two pairs of mutually opposite concavities (valley portions) are formed.

TECHNICAL FIELD

The present invention relates to a polyester pile fabric having a cutpile layer formed from flat polyester filaments and excellent soft hand,abrasion resistance and bathochromic effect.

BACKGROUND ART

A pile fabric has heretofore been used in a large amount for car sheets,home interiors, office interiors, exhibition hall interiors, clothing,and the like. In particular, pile fabrics have been required to exhibitsignificantly excellent properties, and various pile fabrics have beenproposed.

For example, a pile fabric, the bathochromic effect of which is improvedby lowering the content of a delustering agent of the raw yarn for pilesand making the size fall in a specific range, has been proposed inJapanese Unexamined Patent Publication (Kokai) No. 7-102445 (PatentReference 1). Furthermore, a pile fabric, the bathochromic effect ofwhich is improved by using yarns having a necked flat cross-sectionalprofile as pile filaments, is proposed in Japanese Examined UtilityModel Publication (Kokoku) No. 7-40541 (Patent Reference 1) and JapaneseUnexamined Patent Publication (Kokai) No. 10-158953. However, althoughthese pile fabrics are excellent in a bathochromic effect, it cannot besaid that they have a satisfactory soft hand.

On the other hand, a fabric formed from extremely fine filaments hasbeen known as a fabric having a soft hand (e.g., Japanese UnexaminedPatent Publication (Kokai) No. 7-70871). however, when conventionalextremely fine filaments are used as the pile fiber, the total filamentsurface area is increased, and a significant irregular reflection oflight takes place to cause the problem that the dyed fabric thusobtained exhibits a whitish color without deepening the color. Moreover,because the pile filaments have a small individual filament thickness,the fabric has the problem that the individual filaments are likely tobe broken to lower the abrasion resistance.

As explained above, pile fabrics having high soft hand and abrasionresistance and showing a marked bathochromic effect have not beenproposed but are desired.

-   Patent Reference 1: Japanese Unexamined Patent Publication (Kokai)    No. 7-102445-   Patent Reference 2: Japanese Examined Utility Model (Kokoku) No.    7-10541-   Patent Reference 3: Japanese Unexamined Patent Publication (Kokai)    No. 10-158953-   Patent Reference 4: Japanese Unexamined Patent Publication (Kokai)    No. 7-70871

DISCLOSURE OF THE INVENTION

An object of the present invention is to provide a polyester pile fabrichaving a very soft hand, excellent abrasion resistance and bathochromiceffect, and fiber articles thereof.

As a result of intensively carrying out investigations to achieve theabove object, the inventors of the present invention have discoveredthat a desired pile fabric can be obtained by using polyester filamentsyarns having a necked flat cross-sectional profile and a specificindividual pile filament thickness. They have further intensivelyinvestigated to achieve the present invention.

A polyester pile fabric of the present invention comprises a groundstructure portion having a knitted or woven structure formed frompolyester filaments yarns, and a pile portion comprising polyesterfilaments yarns knitted or woven into the ground structure portion,

the pile portion having a cut pile layer formed on one side of theground structure portion and comprising the polyester fibers,

the polyester fibers from which the pile portion is formed, having aindividual fiber thickness of 0.5 to 1.5 dtex and a flat cross-sectionalprofile,

the flat ratio of the flat cross-sectional profile represented by aratio B/C1 wherein B represents the maximum width of the cross-sectionalprofile, and C1 is the maximum thickness of the profile in the directionat right angles to the maximum width direction, being from 2 to 6, andat least two pairs of concavities each pair of which are mutuallyoppositely protruded inward from two sides of the flat cross-sectionfacing each other extending along the maximum width B in the flatcross-sectional profile being formed, whereby the polyester pile fabricshows a very soft hand, high abrasion resistance and a bathochromiceffect.

For the polyester pile fabric of the present invention, the individualfiber thickness of the flat polyester fibers for the pile portion ispreferably from 0.6 to 1.4 dtex.

For the polyester pile fabric of the present invention, the ratio C1/C2wherein C1 represents the maximum thickness of the flat cross-sectionalprofile of the flat polyester fibers for the pile portion, and C2represents the minimum thickness of the profile, is preferably from 1.05to 4.00.

For the polyester pile fabric of the present invention, the flatpolyester filaments for the pile portion preferably comprise adelustering agent in the amount of 2.5% or less by mass or less based onthe mass of the flat polyester filaments.

For the polyester pile fabric of the present invention, the flatpolyester filament yarns for the pile portion are preferably non-twistedyarns.

For the polyester pile fabric of the present invention, the distributiondensity of the flat polyester filament piles in the cut pile layer ispreferably from 5×10⁴ to 20×10⁴ dtex/cm², and a pile density coverfactor defined by the formulaPDF=PN×1/√Dwherein PDF represents a pile density cover factor, PN represents thenumber of pile fibers distributed in an area of 1 cm² of the pile layer,and D represents a pile individual filament thickness (dtex), ispreferably 2×10⁴ or more.

For the polyester pile fabric of the present invention, at least theflat polyester filament yarns from which the pile portion is formed, arepreferably dyed yarns.

Fiber articles of the present invention for interior automotive trims orinteriors of the present invention comprise any of the polyester pilefabrics mentioned above.

According to the present invention, a polyester pile fabric excellent insoft hand, abrasion resistance and bathochromic effect, and fiberarticles for automotive interior trims and home interiors including thepolyester pile fabric can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an explanatory cross-sectional profile of the polyesterpile fabric of the present invention;

FIG. 2 shows an explanatory cross-sectional profile of an example offlat polyester individual fibers for a pile portion contained in apolyester pile fabric of the present invention;

FIG. 3 shows an explanatory cross-sectional profile another example ofthe flat polyester individual fibers for a pile portion contained in apolyester pile fabric of the present invention;

FIG. 4 shows an explanatory cross-sectional profile of still anotherexample of the flat polyester individual fibers for a pile portioncontained in a polyester pile fabric of the present invention; and

FIG. 5 shows a explanatory perspective view of a contact probe used fortesting the hand of the polyester pile fabric of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

In FIG. 1, a polyester pile fabric 1 of the present invention comprisesa ground structure portion 2 having a knitted or woven structure that isformed from polyester filament yarns, and a pile portion 3 formed frompolyester filament yarns 3 a knitted or woven into the ground structureportion 2. The pile portion 3 is formed on one side of the groundstructure portion 2, and has a cut pile layer 3 a formed from the abovepolyester fibers.

The polyester fibers from which the pile portion 3 and also the cut pilelayer 3 a are formed has a individual fiber thickness of 0.5 to 1.5dtex, preferably 0.6 to 1.4 dtex and a flat cross-sectional shape.

The flat ratio of the cross-sectional profile of a flat polyesterindividual fiber for the pile portion represented by the ratio B/C1wherein B represents the maximum width of the cross-sectional profile,and C1 represents the maximum thickness in the direction at right anglesto the maximum width B direction, is from 2 to 6, preferably 3 to 5.

In the flat cross-sectional profile, at least two pairs, preferably 3 to5 pairs of concavities (valley portions), each pair being mutuallyoppositely extend from opposite two sides of the profile along themaximum width B inward of the flat cross section, are formed.

In a cross section 4 of a polyester individual fiber for a pile portionin FIG. 2, mutually oppositely protruded 3 pairs of concavities (valleyportions), namely, a pair 5 a and 5 b, a pair 6 a and 6 b and a pair 7 aand 7 b, are formed from mutually opposite two sides 4 a and 4 b alongthe maximum length B inward of the cross section 4. In FIG. 2, two pairsof projected portions (mountainous portions) are formed on both sides ofeach pair of concavities (valley portions). The concavities 5 a and 5 b,the concavities 6 a and 6 b and the concavities 7 a and 7 b eachoppositely form a pair of concavities which are substantially symmetricwith respect to the centerline 8 in the width direction of the crosssection 4. However, each pair of the concavities is not necessarilyrequired to be strictly symmetric. The ratio C1 /C2 wherein C1represents the maximum width of the cross section, and C2 represents aminimum value of a space between the pair of concavities, is preferablyfrom 1.05 to 4.00, more preferably from 1.10 to 2.50.

A polyester individual fiber having a flat cross-sectional profile, asexplained above, is flat. On a pair of opposite flat surfaces on bothrespective sides of the centerline in the transverse direction of thefilament, at least two pairs of grooves, each pair being mutuallyoppositely protruded toward the inside from the respective flatsurfaces, extend along the longitudinal direction of the flat individualfiber.

That is, polyester individual fibers from which the cut pile layer ofthe pile fabric of the present invention is formed, has a flatcross-sectional profile. On the pair of flat surfaces of the fiber, atleast two pairs of grooves, each pair extending along the longitudinaldirection of the single filament and being mutually opposed, are formed.

In the cross-sectional profile of the flat polyester individual fibersfor the pile portion used in the present invention, when the number ofpairs of constrictions, each formed by a pair of mutually opposite twoconcavity portions, is one or more, the friction coefficient of theperipheral surface of the flat polyester individual fibers from whichthe cut piles are formed, increases and the abrasion resistance becomesinsufficient. Moreover, when the ratio B/C1 of the flat cross-sectionalprofile of the flat polyester individual fiber is less than 2, thebending stiffness of the individual increases, and a desired soft handcannot be obtained. Furthermore, when the ratio exceeds 6, the flat formis deformed or divided by the action of an external force such asabrasion, and the appearance quality is impaired.

Furthermore, the ratio C1 /C2 of a flat polyester individual fibers fromwhich the cut piles are formed, is a parameter related to the depth ofthe concavities (valley portion). When the ratio C1 /C2 is less than1.02 (that is, when the depth of the concavities is too small), thefriction coefficient of the flat polyester individual fibers thusobtained increases, and the abrasion resistance becomes inadequate.Moreover, when the ratio C1 /C2 exceeds 4.00 (that is, when the depth ofthe concavities becomes too large), the improvement effect of theabrasion resistance created by concavities is saturated, and thespinning step is destabilized. As a result, cracks are formed in theindividual fiber along the concavity portion, or uniformity of the shapeand performance of the individual fiber is lowered.

In the flat cross-sectional profile of an individual fiber shown in FIG.3, the depths of concavities (valley) portions 5 a, 5 b, 6 a, 6 b, 7 aand 7 b are relatively shallow, and two pairs of mountainous portions,each pair being on both respective sides of a pair of concavity (valley)portions, form relatively gentle curves. Flat polyester fibers havingsuch a cross-sectional profile are characterized in that they are softand highly lustrous.

In the flat cross-sectional profile of an individual fiber shown in FIG.4, three pairs of concavity (valley portions) and two pairs of mountainportions on both respective sides of each pair of the concavities areformed. The width and height of the mountain portion between theconcavities 6 a and 7 a and those of the mountain portion between theconcavities 6 b and 7 b are smaller than those of the other mountainportions.

The flat polyester individual fibers for a pile portion used in thepresent invention has an individual fiber thickness of 0.5 to 1.5 dtex,preferably 0.6 to 1.4 dtex. When the individual fiber thickness exceeds1.5 dtex, the flexibility of the cut pile layer thus obtained becomesinsufficient. Moreover, when the individual fiber thickness is less than0.5 dtex, the cut pile layer thus obtained has an adequate soft hand.However, the mechanical strength of the cut pile fibers becomesinsufficient, and the abrasion resistance of the cut pile layer becomesinadequate.

The flat polyester fibers for a pile portion used for the pile fabric ofthe present invention preferably contains a delustering agent in anamount of 2.5 mass % or less, more preferably 0 to 1.5 mass % based onthe fiber mass. When the content of a delustering agent exceeds 2.5 mass%, the flat polyester filaments thus obtained sometimes show aninsufficient bathochromic effect. The delustering agent used for theflat polyester filaments of the present invention can be selected fromconventional delustering agents for polyester filaments. However, use ofa delustering agent having a high refractive index (e.g., TiO₂, SiO₂ andBaSO₄) and having an average particle size of about 0.1 to 1 μm ispreferred, and use of a delustering agent containing TiO₂ is morepreferred.

The polyester filaments yarns for a cut pile layer used in the presentinvention are preferably non-twisted yarns. When the yarns are twisted,the bending stiffness of individual filaments increases, and a desiredsoft hand sometimes cannot be obtained. Moreover, the polyester fiberfor the cut pile layer may be crimped, or may not be crimped. Thepolyester filaments can be crimped by a conventional procedure such asfalse twisting, air-jet crimping and compression crimping. In addition,when the polyester filaments are crimped, the percentage of crimp ispreferably 1% or more (more preferably from 1 to 10%).

Although there is no specific restriction on the height of the polyesterfiber piles of the cut pile layer, the pile height is preferably from0.5 to 1.5 mm. When the pile height is less than 0.5 mm, a soft handmight be impaired. Moreover, when the pile height exceeds 1.5 mm, thepile fibers are sometimes laid flat to lower the soft hand of the cutpile layer.

Furthermore, the distribution density of the above polyester fiber pilesin the cut pile layer is preferably from 5×10⁴ to 20×10⁴ dtex/cm², morepreferably from 6×10⁴ to 12×10⁴ dtex/cm², and the pile density coverfactor is preferably 2×10⁴ or more (more preferably from 6×10⁴ to2.5×10⁵). The pile density and the pile density cover factor influencethe bathochromic effect. A higher pile density improves the bathochromiceffect. However, when the pile density exceeds 1.2×10⁵ dtex/cm², thesoft hand might be impaired. Moreover, when the pile density coverfactor is less than 2×10⁴, the pile fibers might be laid flat.

In addition, the pile density may be calculated by counting a number ofindividual fibers per cm², and multiplying the number by the thicknessof the individual fibers. However, for example, when the pile fabric ofthe present invention is a warp knitted fabric, the pile density may becalculated by the following equation: pile density=number of courses percm×number of wales per cm×total thickness (dtex) of yarns for the pile2, wherein the total thickness is the product of the individual fiberthickness (dtex) of the yarn for the piles and the number of individualfibers per yarn. Moreover, the pile density cover factor may be obtainedby directly counting the number of individual fibers per cm², andmultiplying the number by the inverse of the root of the individualfiber thickness. However, for example, when the pile fabric of thepresent invention is a warp knitted fabric, the pile density coverfactor may be calculated by the following equation: Pile density coverfactor=number of courses per cm×number of wales per cm×the inverse ofthe root of the individual fiber thickness (dtex) of the yarn for thepiles×the number of individual fiber per yarn×2, wherein the totalthickness is the product of the individual fiber thickness (dtex) of theyarn for piles and the number of individual fibers per yarn.

That is, the pile density cover factor can be calculated by thefollowing equation:PDF=PN×1/√Dwherein PDF represents the pile density cover factor, PN represents thenumber of pile fibers distributed in an area of 1 cm² of the pile layer,and D represents a thickness (dtex) of a pile individual fibers.

In the present invention, a conventional polyester produced from adicarboxylic acid component and a diglycol component can be used as apolyester resin for forming the flat polyester filaments for a pileportion.

It is preferred that terephthalic acid be mainly used as thedicarboxylic acid component. Moreover, it is preferred that at least onealkylene glycol selected from ethylene glycol, trimethylene glycol andtetramethylene glycol be mainly used as the diglycol component.Moreover, the polyester resin may be made to contain a third componentin addition to the above dicarboxylic acid component and glycolcomponent. Examples of the third component include a cationicdye-dyeable anionic component such as sodiosulfoisophthalic acid,dicarboxylic acids other than terephthalic acid, for example,isophthalic acid, naphthalenedicarboxylic acid, adipic acid, and sebacicacid and glycol compounds other than alkylene glycols such as diethyleneglycol, poly(ethylene glycol), bisphenol A and bisphenolsulfone. Atleast one of these compounds may be used. Furthermore, at least one ofthe following materials may be optionally contained in addition to theabove delustering agents: micropore-forming agents (organic sulfonicacid metal salts), anti-coloring agents, thermal stabilizers, flameretardants (diantimony trioxide), fluorescent brighteners, coloringpigments, antistatic agents (sulfonic acid metal salts), hygroscopicagents (polyoxyalkylene glycols), antibacterial agents and otherinorganic particles.

In addition, the cut pile layer of the pile fabric of the presentinvention is preferably formed out of the polyester cut pile fibersalone. However, the cut pile layer may be made to contain other cut pilefibers as long as the amount is less than 30 wt %.

The ground structure portion of the pile fabric of the present inventionhas a knitted or woven structure formed out of a polyester filamentsyarn. The above-mentioned polyester resins may be used for forming thepolyester filaments for the ground structure. The content of adelustering agent is not specifically limited. Moreover, in view of notimpairing the hand of the fabric, individual fiber thickness and totalsize of the polyester filaments yarn for the ground structure arepreferably from 0.5 to 5.0 dtex and from 30 to 300 dtex, respectively.Furthermore, there is no specific restriction on the cross-sectionalprofile of the individual fibers. The cross-sectional profile may betriangular, flat, flat and necked, cross, hexagonal or hollow inaddition to being round. Still furthermore, the polyester filament yarnmay be false twisted yarn or a composite yarn in which at least twoconstituent yarns are air-jet combined or composite false twisted, or itmay be a covered yarn in which an elastic yarn is placed in the coreportion and an inelastic yarn is placed in the sheath portion.

There is no specific limitation on the knitted or woven structure of thepile fabric in the present invention. Examples of the structure includea pile fabric obtained by cutting a loop pile of a fabric such as a warppile woven fabric, a weft pile woven fabric, a sinker pile knittedfabric, a raschel pile knitted fabric or a tricot pile knitted fabric,and a pile fabric obtained by center-cutting a pile woven fabricprepared with a moquette (double weave) weaving machine.

The pile fabric of the present invention can be produced by, forexample, the following production process.

First, polyester filament yarns for pile portion having a flat crosssection with at least 2 necked portions and a cross-sectional flat ratioof 2 to 6, and an individual fiber thickness of 1.5 dtex or less isproduced by, for example, spinning a polyester resin through a spinnerethaving injection nozzles as shown in FIG. 2 C on page 5 in JapaneseUnexamined Patent Publication (Kokai) No. 56-107044. On the other hand,a polyester filament yarns for the ground structure portion is producedby spinning a polyester resin using a conventional spinneret. A pilefabric is produced from both yarns.

The pile portion having a knitted fabric structure is formed during theproduction by the following procedure. The ground structure is knitted,and a loop pile structure extending thereabove such as a sinker pile, apole tricot pile or a double raschel pile is formed, followed by forminga cut pile layer by cutting the loop pile. The pole tricot pile isobtained by forming the pile knitted portion of a tricot knittedstructure into a loop pile with a raising machine.

On the other hand, the pile portion having a woven fabric structure isformed by the following procedure. A warp pile or weft pile woven fabricis woven, and the loop pile is cut to form a cut pile layer; or amoquette woven fabric is woven, and the pile yarn is center cut to forma cut pile layer.

The pile fabric of the present invention is usually preset by a dry heattreatment, and then conventionally dried and final dry heat treated. Thepreset dry heat treatment temperature is preferably from 150 to 200° C.,and the dyeing temperature is preferably from 130 to 135° C. The finaldry heat treatment temperature is preferably from 140 to 160° C.

In addition, another known layer such as a back coating layer or a pilelayer may be formed on the side opposite to the cut pile layer in theground structure portion of the pile fabric of the present invention.Moreover, the opposite side may be subjected to patterning byconventional etching, embossing, alkali reduction, color printing, waterrepellent finishing, and other various processes for imparting agentssuch as a UV shielding agent, an antibacterial agent, a deodorant, amothproofing agent, a luminous agent, a retroreflecting agent and anegative ion-generating agent.

The polyester fibers of the cut pile layer in the pile fabric of thepresent invention thus obtained have a flat cross section, and theindividual fiber thickness is as small as 1.5 dtex or less. As a result,the bending stiffness is low, and a good soft hand is obtained.Moreover, because constrictions are formed in the flat cross sectionalprofile, the contact area formed when another material is contacted withthe cut pile layer is decreased. As a result, the friction resistance issmall, and an excellent abrasion resistance is obtained. At the sametime, the roughening effect of the constrictions produces the effect ofgiving a high bathochromic effect.

EXAMPLES

The present invention is explained in detail by making reference to thefollowing examples. However, the present invention is in no wayrestricted thereto. In addition, physical properties in the exampleswere determined by the following methods.

(1) Hand

A surface property tester (trademark: KES F4, manufactured by Kato TechCo., Ltd.) was used. A fabric to be tested is cut to give a test peace,20 cm×20 cm. The test peace was pressed with the bottom face of acontact probe having been prepared by bending 10 piano wire pieces eachhaving a diameter of 0.5 mm under a load of 98 mN (10 gf). The surfacefriction coefficient p of the test peace in the warp direction and thatin the weft direction were each determined at a moving speed of the testpeace of 0.1 cm/sec under a measurement tension of 196 mN (20 gf)/cm. Inaddition, the number of n was 5, and the average value was obtained.

(2) Abrasion Resistance 1

The abrasion resistance of a specimen of a fabric was evaluated inaccordance with JIS L 1096-1990, 6.32 4 D method (Martin Dale method).The specimen was rotated 20,000 times, and the change in color byabrasion is evaluated on a gray scale for a change in color. Inaddition, the number of n was 5, and the average value was obtained.

(3) Abrasion Resistance 2

The pile fallout by abrasion of a fabric was evaluated in accordancewith JIS L 0894 Gakushin tester method. The fabric to be tested was cutto give a test piece, 20 cm×3 cm. The test peace was rotated 10,000times under a load of 9.8 N (1.0 kgf), and the pile fallout by abrasionof the test peace was evaluated. In addition, the number of n was 5, andthe average value was obtained.

(4) Surface Appearance

The laying flat state of pile fibers was visually observed, andevaluated according to the following criteria: Excellent: good withoutlaying flat; Good: usual; and Bad: not good with laying flat.

(5) Bathochromic Effect

Using a Macbeth Color Eye Model M 2020 (manufactured by Kolmorgen Corp.in U.S.A.), an L value of a test fabric was measured. The light sourcewas D65 standard light, and the observation angle was 10°. In addition,the number of n was 5, and the average value was determined.

Example 1

A poly(ethylene terephthalate) resin containing no delustering agent(titanium oxide) was extruded at a spinning temperature of 300° C.through 72 melt spinning nozzles each having a cross-sectional profilecorresponding to a filament cross-sectional profile shown in FIG. 2(each spinning nozzle having 4 circular arc-like projected portions oneach of both sides of the longitudinal center line, and 3 concavityportions formed between the adjacent circular arc-like projectedportions). The extruded yarn was drawn by a conventional method to givea drawn multifilaments yarn having a yarn count of 88 dtex/72 filaments(individual fiber thickness of 1.2 dtex) for yarns for pile yarns. Theyarn for a pile yarn was composed of filaments (individual filaments)each having a cross-sectional profile as shown in FIG. 2. Thecross-sectional flat ratio (B/C1) of the cross-sectional profile was3.2. In the flat cross section, the ratio (C1 /C2) of a maximum value(C1) of the width to a minimum value (C2) thereof was 1.2.

On the other hand, a drawn multifilaments yarn having a yarn count of 84dtex/36 filaments were prepared by extruding a conventionalpoly(ethylene terephthalate) resin through melt spinning nozzles havinga regular round cross sectional profile to spin a yarn and drawing thespun yarn. A drawn yarn usable as a middle yarn for pile fabric wasobtained. Moreover, a false twisted multifilaments yarn having a yarncount of 84 dtex/36 filaments was prepared by extruding a conventionalpoly(ethylene terephthalate) resin through melt spinning nozzles havinga regular round cross-sectional profile to spin a yarn, drawing the spunyarn, and conventionally false twisting and crimping the drawn yarn. Theresultant yarn was usable as a ground yarn for pile fabric.

Next, using a tricot warp knitting machine manufactured by Karl Meyer, aknitted fabric having a course density of 86 courses/2.54 cm and a waledensity of 28 wales/2.54 cm was formed with a swing indication of thebar for the pile yarn of 1034, a swing indication of the bar for themiddle yarn of 1023 and a swing indication of the bar for the groundyarn of 1012. The loop pile fabric thus obtained was supplied to adyeing step, and dyed at 130° C. for 45 minutes with a fluid-streamdyeing machine (manufactured by Hisaka Works, Ltd.) with the followingdye composition.

-   -   (Dyeing bath):    -   Teratop Blue HLB (trade name, manufactured by Ciba Geigy) 0.4%        (based on the fabric mass)    -   Irgasol Dam (trade name, manufactured by Ciba Geigy)    -   1 g/liter    -   Acetic acid 0.5 g/liter        After dyeing, the resultant dried fabric was placed in a short        loop drier (manufactured by Hirano Tecseed Co., Ltd.), to dry        it. The dried fabric was subjected to raising agent treatment        using a padding machine (manufactured by Hirano Tecseed Co.,        Ltd.), and supplied to a drying setter where the fabric was        preset by a dry heat treatment at 170° C. for 1 minute while the        fabric was held in a open-width state. The tip portions of the        loop piles were then raised and cut with a card clothing raising        machine (manufactured by Nikki Co., Ltd.). The tip portions of        the loop piles were then sheared with a shearing machine        (manufactured by Nikki Co., Ltd.) to form cut piles (pile height        of 1 mm). The cut piles thus obtained were subjected to final        dry heat treatment at 160° C. for 1 minute with a drying setter        (manufactured by Hirano Tecseed Co., Ltd.) to give a pile fabric        having a course density of 79 curses/2.54 cm and a wale density        of 43 wales/2.54 cm.

The pile fabric thus obtained had the following properties: a piledensity of 9.27×10⁴ dtex/cm²; a pile density cover factor of 6.86×10⁴;an individual fiber thickness of the polyester cut pile fibers of 1.2dtex; a bathochromic effect in terms of L value of 4.92; an abrasionresistance 1 (by Martin Dale method) of class 3 to 4; an abrasionresistance 2 (Gakushin tester method) of class 3; a surface frictioncoefficient μ in the warp direction of 0.32; a surface frictioncoefficient μ in the weft direction of 0.297; and an excellent surfaceappearance. The fabric therefore had a high soft hand, a high abrasionresistance and a significant bathochromic effect.

Comparative Example 1

A pile fabric was produced in the same manner as in Example 1 withexceptions as explained below. The yarn for a pile yarn was produced byextruding a conventional poly(ethylene terephthalate) resin through aregular round cross-sectional melt spinning nozzles to spin a yarn, anddrawing the spun yarn. The resultant drawn multifilaments yarn had ayarn count of 56 dtex/144 filaments. A knitted fabric having a coursedensity of 90 courses/2.54 cm and a wale density of 28 wales/2.54 cm wasformed out of the drawn multifilament yarn. The pile fabric obtainedfrom the knitted fabric had a course density of 79 courses/2.54 cm and awale density of 43 wales/2.54 cm.

The pile fabric thus obtained had the following properties: a piledensity of 5.61×10⁴ dtex/cm²; a pile density cover factor of 2.31×10⁵;an individual fiber thickness of the polyester cut pile fibers of 0.39dtex; a bathochromic effect in terms of L value of 6.64; an abrasionresistance 1 (by Martin Dale method) of class 3; an abrasion resistance2 (Gakushin tester method) of class 2; a surface friction coefficient μin the warp direction of 0.313; a surface friction coefficient μ in theweft direction of 0.325; and an excellent surface appearance. The fabrictherefore had a poor abrasion resistance and a poor color deepeningeffect.

Comparative Example 2

A pile fabric was produced in the same manner as in Example 1 with theexceptions explained below. The yarn for a pile yarn was produced byextruding a conventional poly(ethylene terephthalate) resin through aregular flat cross-sectional melt spinning nozzles to a yarn, anddrawing the spun yarn. The drawn multifilaments yarn was a flat filamentyarn having no constrictions, and had a yarn count of 88 dtex/72filaments. A knitted fabric having a course density of 90 courses/2.54cm and a wale density of 28 wales/2.54 cm was formed out of the drawnmultifilaments yarn. The pile fabric obtained from the knitted fabrichad a course density of 79 courses/2.54 cm and a wale density of 43wales/2.54 cm.

The pile fabric thus obtained had the following properties: a piledensity of 9.26×10⁴ dtex/cm²; a pile density cover factor of 6.86×10⁴;an individual fiber thickness of the polyester cut pile fibers of 1.2dtex; a bathochromic effect in terms of L value of 5.64; an abrasionresistance 1 (Martin Dale method) of class 3; an abrasion resistance 2(Gakushin tester method) of class 2; a surface friction coefficient μ inthe warp direction of 0.313; a surface friction coefficient μ in theweft direction of 0.325; and an excellent surface appearance. The fabrictherefore had a poor abrasion resistance and a poor bathochromic effect.

INDUSTRIAL APPLICABILITY

The pile fabric of the present invention has a satisfactory soft hand,high abrasion resistance and bathochromic effect, and thus can be usedfor automotive interior trims such as car sheets and ceiling members,home and office interiors such as upholsteries and carpets, exhibitionhall interiors and fiber articles such as clothing. Accordingly, theindustrial value of the pile fabric is extremely great.

1. A polyester pile fabric comprising a ground structure portion havinga knitted or woven structure formed from polyester filaments yarns, anda pile portion comprising a polyester filament yams knitted or woveninto the ground structure portion, the pile portion having a cut pilelayer formed on one side of the ground structure portion and comprisingthe polyester fibers, the polyester fibers, form which the pile portionis formed, having an individual fiber thickness of 0.5 to 1.5 dtex and aflat cross-sectional profile, the flat ratio of the flat cross-sectionalprofile represented by a ratio B/C1 wherein B represents the maximumwidth of the cross-sectional profile, and C1 represents the maximumthickness the profile in the direction at right angles to the maximumwidth direction, being from 2 to 6, and at least two pairs ofconcavities each pair of which are mutually oppositely protruded inwardfrom the two sides of the flat cross section facing each other extendingalong the maximum width B in the flat cross-sectional profile beingformed, whereby the polyester pile fabric exhibits high soft hand,abrasion resistance and bathochromic effect.
 2. The polyester pilefabric according to claim 1, wherein the individual fiber thickness ofthe flat polyester fibers for the pile portion is from 0.6 to 1.4 dtex.3. The polyester pile fabric according to claim 1, wherein the ratio C1/C2 wherein C1 represents the maximum thickness in the flatcross-sectional profile of the flat polyester fibers for the pileportion, and C2 is the minimum thickness in the profile, is from 1.05 to4.00.
 4. The polyester pile fabric according to claim 1, wherein theflat polyester filaments for the pile portion contain a delusteringagent in an amount of 2.5% or less by mass based on the mass of the flatpolyester filaments.
 5. The polyester pile fabric according to claim 1,wherein the flat polyester filament yarns for the pile portion arenon-twisted yarns.
 6. The polyester pile fabric according to claim 1,wherein the distribution density of the flat polyester fiber piles inthe cut pile layer is from 5×10⁴ to 20×10⁴ dtex/cm², and a pile densitycover factor defined by the formula;PDF=PN×1/√D wherein PDF represents a pile density cover factor, PNrepresents the number of pile fibers distributed in an area of 1 cm² ofthe pile layer, and D represents a pile individual filament thickness(dtex), is 2×10⁴ or more.
 7. The polyester pile fabric according toclaim 1, wherein at least the flat polyester filament yams from whichthe pile portion is are dyed yams.
 8. Fiber articles for interiorautomotive trims or interiors comprising the polyester pile fabricaccording to claim
 1. 9. Fiber articles for interior automotive trims orinteriors comprising the polyester pile fabric according to claim
 2. 10.Fiber articles for interior automotive trims or interiors comprising thepolyester pile fabric according to claim
 3. 11. Fiber articles forinterior automotive trims or interiors comprising the polyester pilefabric according to claim
 4. 12. Fiber articles for interior automotivetrims or interiors comprising the polyester pile fabric according toclaim
 5. 13. Fiber articles for interior automotive trims or interiorscomprising the polyester pile fabric according to claim
 6. 14. Fiberarticles for interior automotive trims or interiors comprising thepolyester pile fabric according to claim 7.